Graco saniforce 2150 User manual

Repair/Parts
SaniForce®2150,3000,4000,
Electric-OperatedDiaphragm
Pump3A5133J
EN
2 2
2- - -Inch, Inch, Inch,3 3 3- - -Inch, Inch, Inch,and and and4 4 4- - -Inch Inch Inchpumps pumps pumpswith with withelectric electric electricdrive drive drivefor for for󰘱uid 󰘱uid 󰘱uidtransfer transfer transferapplications. applications. applications.
Not Not
Notapproved approved approvedfor for foruse use usein in inexplosive explosive explosiveatmospheres atmospheres atmospheresor or orhazardous hazardous hazardouslocations locations locationsunless unless unlessotherwise otherwise otherwisestated. stated. stated.See See See
Approvals Approvals
Approvalspage page pagefor for formore more moreinformation. information. information.For For Forprofessional professional professionaluse use useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanualandinyour
Operationmanual.Save Save
Savethese these theseinstructions. instructions. instructions.
Formaximumworkingpressure,see
TechnicalDatasheets
Seepage7forapprovals.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
RelatedManuals................................................2
Warnings...........................................................3
Con󰘰gurationNumberMatrix...............................6
OrderingInformation...........................................8
Troubleshooting..................................................9
Repair................................................................11
PressureReliefProcedure............................11
CheckValveRepair.....................................11
StandardDiaphragmRepair.........................14
OvermoldedDiaphragmRepair.....................16
CenterSectionRepair..................................18
ReplacetheCompressor..............................23
Parts..................................................................24
KitsandAccessories....................................33
TechnicalData...................................................34
Related Related
RelatedManuals Manuals Manuals
ManualNumberTitle
3A5132SaniForce™2150,3000,4000,Electric-OperatedDiaphragmPump,Operation
23A5133J

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
DANGER
SEVERE SEVERE
SEVEREELECTRIC ELECTRIC ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Thisequipmentcanbepoweredbymorethan240V.Contactwiththisvoltagewill
causedeathorseriousinjury.
•Turnoffanddisconnectpoweratmainswitchbeforedisconnectinganycablesand
beforeservicingequipment.
•Thisequipmentmustbegrounded.Connectonlytogroundedpowersource.
•Allelectricalwiringmustbedonebyaquali󰘰edelectricianandcomplywithalllocal
codesandregulations.
WARNING
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,inwork work
workarea area areacanigniteorexplode.Paint
orsolvent󰘱owingthroughtheequipmentcancausestaticsparking.Tohelpprevent󰘰reand
explosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticarc).
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Useonlygroundedhoses.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock. . .Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
Staticchargemaybuilduponplasticpartsduringcleaningandcoulddischargeandignite
󰘱ammablevapors.Tohelpprevent󰘰reandexplosion:
•Cleanplasticpartsonlyinwellventilatedarea.
•Donotcleanwithadrycloth.
•Donotoperateelectrostaticgunsinequipmentworkarea.
3A5133J3

Warnings
WARNING
PRESSURIZED PRESSURIZED
PRESSURIZEDEQUIPMENT EQUIPMENT EQUIPMENTHAZARD HAZARD HAZARD
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopspraying/dispensingandbefore
cleaning,checking,orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhoses,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalData Data Datainallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
TechnicalData Data Data
inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcomplete
informationaboutyourmaterial,requestSafetyDataSheet(SDS)fromdistributororretailer.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
PRESSURIZED PRESSURIZED
PRESSURIZEDALUMINUM ALUMINUM ALUMINUMPARTS PARTS PARTSHAZARD HAZARD HAZARD
Useof󰘱uidsthatareincompatiblewithaluminuminpressurizedequipmentcancauseserious
chemicalreactionandequipmentrupture.Failuretofollowthiswarningcanresultindeath,
seriousinjury,orpropertydamage.
•Donotuse1,1,1-trichloroethane,methylenechloride,otherhalogenatedhydrocarbon
solventsor󰘱uidscontainingsuchsolvents.
•Donotusechlorinebleach.
•Manyother󰘱uidsmaycontainchemicalsthatcanreactwithaluminum.Contactyourmaterial
supplierforcompatibility.
43A5133J

Warnings
WARNING
THERMAL THERMAL
THERMALEXPANSION EXPANSION EXPANSIONHAZARD HAZARD HAZARD
Fluidssubjectedtoheatincon󰘰nedspaces,includinghoses,cancreatearapidriseinpressure
duetothethermalexpansion.Over-pressurizationcanresultinequipmentruptureandserious
injury.
•Openavalvetorelievethe󰘱uidexpansionduringheating.
•Replacehosesproactivelyatregularintervalsbasedonyouroperatingconditions.
PLASTIC PLASTIC
PLASTICPARTS PARTS PARTSCLEANING CLEANING CLEANINGSOLVENT SOLVENT SOLVENTHAZARD HAZARD HAZARD
Manysolventscandegradeplasticpartsandcausethemtofail,whichcouldcauseserious
injuryorpropertydamage.
•Useonlycompatiblewater-basedsolventstocleanplasticstructuralorpressure-containing
parts.
•SeeTechnical Technical
TechnicalData Data Datainthisandallotherequipmentinstructionmanuals.Read󰘱uidand
solventmanufacturer’sSafetyDataSheet(SDS)andrecommendations.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMESHAZARD HAZARD HAZARD
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadSafetyDataSheet(SDS)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
BURN BURN
BURNHAZARD HAZARD HAZARD
Equipmentsurfacesand󰘱uidthat’sheatedcanbecomeveryhotduringoperation.Toavoid
severeburns:
•Donottouchhot󰘱uidorequipment.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective
equipmentincludesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
3A5133J5

CongurationNumberMatrix
Con󰘰guration Con󰘰guration
Con󰘰gurationNumber Number NumberMatrix Matrix Matrix
Checktheidenti󰘰cationplate(ID)forthe
Con󰘰gurationNumberofyourpump.Usethe
followingmatrixtode󰘰nethecomponentsofyour
pump.
Sample Sample
SampleCon󰘰guration Con󰘰guration Con󰘰gurationNumber: Number: Number:2150TE,A04AS1 2150TE,A04AS1
2150TE,A04AS1- - -3SSPTPTPT 3SSPTPTPT 3SSPTPTPT
2150 2150
2150T T
TE E EA A A04 04
04A A
AS1 S1
S1- - -3 3 3SS SS SSPT PT
PTPT PT PTPT PT PT
Pump
Model
Wetted
Section
DriveCenter
Section
Gear
Boxand
Compressor
MotorFluidCoversand
Manifolds
SeatsBalls
orChe-
cks
DiaphragmsManifold
Seals
Certi󰘰ca-
tion
Pump Pump
PumpWetted Wetted
WettedSection Section SectionDrive Drive
DriveType Type TypeCenter Center
CenterSection Section Section
Material Material
Material
Gearbox Gearbox
Gearboxand and and
Compressor Compressor
Compressor
Motor Motor
Motor
2150 2150
2150T T
TFoodGradeE E EElectricA A
AAluminum94 94
94NoGearboxor
CompressorA A
AStandard
InductionMotor
3000 3000
3000HS HS HSHighSanitationS S SStainlessSteel04 04 04HighSpeedGear
RatioC C
CATEXInduction
Motor
4000 4000
40003A 3A 3A3ACerti󰘰ed05 05 05HighSpeed
GearRatio/120V
Compressor
D D
DFlameproof
InductionMotor
PH PH
PHPharmaceutical06 06
06HighSpeed
GearRatio/240V
Compressor
G G
GNoMotor
14 14
14MidSpeedGear
Ratio
15 15
15MidSpeed
GearRatio/120V
Compressor
16 16
16MidSpeed
GearRatio/240V
Compressor
24 24
24LowSpeedGear
Ratio
25 25
25LowSpeed
GearRatio/120V
Compressor
26 26
26LowSpeed
GearRatio/240V
Compressor
63A5133J

CongurationNumberMatrix
Fluid Fluid
FluidCovers Covers Coversand and and
Manifolds Manifolds
Manifolds
Seat Seat
SeatMaterial Material MaterialBall Ball Ballor or orCheck Check CheckMaterial Material MaterialDiaphragm Diaphragm
DiaphragmMaterial Material MaterialManifold Manifold
Manifold
Seals Seals
Seals
EN EN
EN10204 10204 10204
Certi󰘰cation Certi󰘰cation
Certi󰘰cation
S1 S1
S1- - -3 3 3Stainless
steel,
TriClamp
FL FL
FL316
Stainless
Steel
Flapper
— —
—Flapper,check,
StainlessSteelEO EO
EOEPDM
OvermoldedEP EP
EPEPDM<blank>
nocerti󰘰cation
S1 S1
S1- - -4 4 4Stainless
steel,DINSS SS
SS316
Stainless
Steel
BN BN
BNBuna-NFK FK FKFKM
FluoroelastomerPT PT
PTPTFEC21 C21
C21
2.1certi󰘰ed
S– S–
S–Stainless
steel,no
manifolds
CW CW
CWPolychloroprene
WeightedPS PS
PSPTFE/Santo-
prene
2–Piece
C31 C31
C31
3.1certi󰘰ed
SSA SSA
SSAStainless
Steel,
Tri-Clamp
(HS/3-A/PH)
FK FK
FKFKM
FluoroelastomerPT PT
PTPTFE/EPDM
2–Piece
SSB SSB
SSBStainless
Steel,DIN
(HS/3-A/PH)
PT PT
PTPTFESP SP
SPSanto-
prene/EPDM
2–Piece
SP SP
SPSantoprene
Approvals Approvals
Approvals
✦PumpswithmotorcodeCarecerti󰘰edto:
II2GExdhIIBT3Gb
✚PumpswithmotorcodeGarecerti󰘰edto:
II2GExhIIBT3Gb
★MotorscodedDarecerti󰘰edto:
ClassI,Div1,GroupD,T3B
ClassII,Div1,GroupF&G,T3B
BallmaterialscodedPTanddiaphragm
materialscodedPTarecerti󰘰edto:
EC1935
AllModels(exceptgearboxandcompressor
codes05,15,and25,ormotorcodeD)are
certi󰘰edto:
3A5133J7

OrderingInformation
Ordering Ordering
OrderingInformation Information Information
To To
ToFind Find FindYour Your YourNearest Nearest NearestDistributor Distributor Distributor
Visitwww.graco.com
To To
ToSpecify Specify Specifythe the theCon󰘰guration Con󰘰guration Con󰘰gurationof of ofa a aNew New NewPump Pump Pump
Please Please
Pleasecall call callyour your yourdistributor. distributor. distributor.
OR OR
OR
UsetheOnline Online
OnlineDiaphragm Diaphragm DiaphragmPump Pump PumpSelector Selector SelectorTool Tool Toolat at atwww.graco.com www.graco.com www.graco.com. . .SearchforSelector Selector Selector.
To To
ToOrder Order OrderReplacement Replacement ReplacementParts Parts Parts
Please Please
Pleasecall call callyour your yourdistributor. distributor. distributor.
83A5133J

Troubleshooting
Troubleshooting Troubleshooting
Troubleshooting
•FollowthePressureReliefProcedure,page11,
beforecheckingorservicingtheequipment.
•Checkallpossibleproblemsandcausesbefore
disassembly.
Problem Problem
ProblemCause Cause CauseSolution Solution Solution
Pumpisrunningtoofast,causing
cavitationbeforeprime.
Slowdownthecontroller(VFD)
Centersectionhasnoairpressure,
orairpressureistoolow.
Applyairpressuretocentersection
peryourapplicationrequirements.
Checkvalveballisseverelywornor
wedgedinseatormanifold.
Replacetheballandseat.
Thepumphasinsuf󰘰cientsuction
pressure.
Increasethesuctionpressure.See
theOperationmanual.
Seatisseverelyworn.Replacetheballandseat.
Outletorinletisrestricted.Removetherestriction.
Inlet󰘰ttingsormanifoldsareloose.Tighten.
Pumpcyclesbutwillnot
primeand/orpump.
Manifoldo-ringsaredamaged.Replaceo-rings.
Thecentersectionis
excessivelyhot.
Thedriveshaftisbroken.Replace.
Checkvalveballs,seats,oro-rings
areworn.
Replace.
Manifoldscrewsor󰘱uidcover
screwsareloose.
Tighten.
Pumpfailstohold󰘱uid
pressureatstall.
NOTE: NOTE:
NOTE:Flapperchecks
arenot100%󰘱uidtight.
DiaphragmshaftboltislooseTighten.
Motororcontrolleriswired
improperly.
Wirepermanual. Pumpwillnotcycle.
Theleakdetector(ifinstalled)has
tripped.
Checkdiaphragmforruptureor
incorrectinstallation.Repairor
replace.
Themotorisoperating,
butthepumpwillnot
cycle.
Thejawcouplingbetweenthe
motorandgearboxisnotconnected
properly.
Checktheconnection.
Suctionlineisclogged.Inspect;clear.
Checksarestickyorleaking.Cleanorreplace.
Pump󰘱owrateiserratic.
Diaphragm(orbackup)ruptured.Replace.
Pumpmakesunusual
noises.
Pumpisoperatingnearoratstall
pressure.
Adjustairpressureorslowthepump
speed.
3A5133J9

Troubleshooting
Problem Problem
ProblemCause Cause CauseSolution Solution Solution
A󰘰ttingisloose.Tighten.Inspectthreadsealant.
Looseordamagedo-ringsorshaft
seal.
Replace.
Airconsumptionishigher
thanexpected.
Diaphragm(orbackup)ruptured.Replace.
Suctionlineisloose.Tighten.
Diaphragm(orbackup)ruptured.Replace.
Loosemanifolds,damagedseatsor
o-rings.
Tightenmanifoldboltsorreplace
seatsoro-rings.
Airbubblesin󰘱uid.
Loosediaphragmshaftbolt.Tighten.
Loosemanifoldscrewsor󰘱uidcover
screws.
Tighten.
Pumpleaks󰘱uid
externallyfromjoints.
Manifoldo-ringswornout.Replaceo-rings.
AGFCIhastripped.Removethecontrollerfromthe
GFCIcircuit.
Supplypowerispoor.Determineand󰘰xthesourceofthe
powerproblem.
Thecontrollerfaultsor
shutsdown.
Operationalparametersare
exceeded.
Seeperformancechart;ensure
pumpisoperatingwithinthe
continuousdutyrange.
Inletcheckclogged/improperly
installed
Removedebris/installproperly Excessivemotor
regenerationfaultfrom
VFDBrokendiaphragmboltReplacebolt
NOTE: NOTE:
NOTE:ForproblemswithaVariableFrequencyDevice(VFD),seeyourVFDmanual.
103A5133J

Repair
Repair Repair
Repair
Pressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedure
FollowthePressureReliefProcedure
wheneveryouseethissymbol.
Thisequipmentstayspressurizeduntilpressure
isrelievedmanually.Tohelppreventserious
injuryfrompressurized󰘱uid,suchassplashing
intheeyesoronskin,followthePressureRelief
Procedurewhenyoustoppumpingandbeforeyou
clean,check,orservicetheequipment.
1.Removepowerfromthesystem.
2.Openthedispensingvalve,ifused.
3.Openthe󰘱uiddrainvalvetorelieve󰘱uid
pressure.Haveacontainerreadytocatchthe
drainage.
4.Backoutregulatorknobtobleedanyinternal
airpressure.
Check Check
CheckValve Valve ValveRepair Repair Repair
Tools Tools
ToolsRequired Required Required
•O-ringpick
NOTE: NOTE:
NOTE:Kitsareavailablefornewcheckvalveballs
andseatsinarangeofmaterials.O-ringkitsalso
areavailable.
NOTE: NOTE:
NOTE:Toensureproperseatingofthecheckballs,
alwaysreplacetheseatswhenreplacingtheballs.
Also,replacetheo-ringseverytimethemanifoldis
removed.
Disassemble Disassemble
Disassemblethe the theBall Ball BallCheck Check CheckValve Valve Valve
1.FollowthePressureReliefProcedure,page11.
Removepowerfromthemotor.Disconnectall
hoses.
2.Removetheclamps(31)holdingtheoutlet
manifold(3)tothe󰘱uidcovers(2),thenremove
theoutletmanifold.
3.Removetheballcheckvalveassemblies:
a.Onthe2150T,removetheseats(6),balls
(7),ando-rings(8).
b.Onthe2150HS,removetheballstops(28),
balls(7),andgaskets(8a).
4.Repeatfortheinletmanifold.
Tocontinuedisassembly,see
DisassembletheStandardDiaphragms,page14.
Reassemble Reassemble
Reassemblethe the theBall Ball BallCheck Check CheckValve Valve Valve
1.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.
2.Reassembleinthereverseorder,followingall
notesintheillustration.Puttheinletmanifoldon
󰘰rst.Besuretheballchecksandmanifoldsare
assembledexactly exactly
exactlyasshown.Ifpresentonthe
󰘱uidcovers(2),thearrows(A)must must
mustpointtoward
theoutletmanifold(3).For󰘱uidcoverswithout
arrows,thetallestopeninginthe󰘱uidcovermust must
must
beattachedtotheoutletmanifold.
3A5133J11

Repair
1
Arrow(A)mustpointtowardoutlet
manifold.
2
Radiusedseatingsurfacemustfacethe
ball(7).LargechampferonO.D.mustface
o-ring.
123A5133J

Repair
Disassemble Disassemble
Disassemblethe the theFlapper Flapper FlapperCheck Check CheckValve Valve Valve
1.FollowthePressureReliefProcedure,page11.
Removepowerfromthemotor.Disconnectall
hoses.
2.Removetheclamps(31)holdingtheoutlet
manifold(3)tothe󰘱uidcovers,thenremovethe
outletmanifold.
3.Removethe󰘱appers(7a),andgaskets(8a).
4.Repeatstepstoremovetheinletmanifold(4).
Removethe󰘱appers(7a),andgaskets(8a).
Tocontinuedisassembly,see
DisassembletheStandardDiaphragms,page14.
Reassemble Reassemble
Reassemblethe the theFlapper Flapper FlapperCheck Check CheckValve Valve Valve
1.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.
2.Reassembleinthereversedisassemblyorder.
Puttheinletmanifoldon󰘰rst.Besurethe󰘱apper
checksandmanifoldsareassembledexactly exactly
exactlyas
shown.
3A5133J13

Repair
Standard Standard
StandardDiaphragm Diaphragm DiaphragmRepair Repair Repair
Tools Tools
ToolsRequired Required Required
•Torquewrench
•10mmhexkeywrench
•28mmopenendwrench
•O-ringpick
Disassemble Disassemble
Disassemblethe the theStandard Standard StandardDiaphragms Diaphragms Diaphragms
NOTE: NOTE:
NOTE:Diaphragmkitsareavailableinarangeof
materialsandstyles.SeePartssection.
1.FollowthePressureReliefProcedure,page11.
Removepowerfromthemotor.Disconnectall
hoses.
2.Removethemanifoldsanddisassemble
theballcheckvalvesasexplainedin
CheckValveRepair,page11.
3.Removetheclamps(30)fromthe󰘱uidcovers,
thenpullthe󰘱uidcoversoffofthepump.
4.Toremovethediaphragms,thepistonmust
bemovedfullytooneside.Ifthepumpisnot
attachedtothegearbox,turntheshaftbyhand
tomovethepiston.Ifthepumpisstillattached
tothegearbox,loosenthescrewsandremove
thefancover.Turnthefanbyhandtorotatethe
shafttoshiftthepistontooneside.
TIP: TIP:
TIP:Theaircoverhas2holes(H),oneatthe
9o’clockpositionandanotheratthe3o’clock
position.Usepin(131),placedineitherhole
(H)asabraceforthewrenchwhileremovingor
installingdiaphragmbolts.
a.Holda28mmwrenchonthewrench󰘱ats
oftheexposedpistonshaft.Useanother
wrench(10mmhexkey)ontheshaftbolt
(13)toremoveit.Thenremoveallpartsof
thediaphragmassembly.
b.Rotatethedriveshafttomovethepistonfully
totheotherside.Repeatstep4a.
5.Tocontinuewithdisassembly,see
DisassembletheCenterSection,page18.
143A5133J

Repair
Reassemble Reassemble
Reassemblethe the theStandard Standard StandardDiaphragms Diaphragms Diaphragms
NOTICE NOTICE
NOTICE
Afterreassembly,allowthethreadlockertocure
for12hours,orpermanufacturer’sinstructions,
priortooperatingthepump.Damagetothepump
willoccurifthediaphragmshaftboltloosens.
TIP: TIP:
TIP:Ifyouarealsorepairingorservicingthe
centersection(driveshaft,piston,etc.),see
CenterSectionRepair,page18,beforeyouputthe
diaphragmsbackon.
1.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.Besurethecenter
sectioniscleananddry.
2.Thoroughlycleanorreplacethediaphragmbolt
(13).Installtheo-ring(34).
3.Assemblethe󰘱uidsideplate(9),thediaphragm
(11),thebackupdiaphragm(12,ifpresent),and
theairsidediaphragmplate(10)onthebolt
exactlyasshown.
4.Cleanthefemalethreadsofthepistonshaft
withawirebrushdippedinsolventtoremove
anyresidualthreadlocker.Applythread-locking
primerandallowittodry.
5.Applymedium-strength(blue)threadlockerto
thethreadsofthebolt.
6.Holda28mmwrenchonthewrench󰘱atsofthe
pistonshaft.Screwtheboltontotheshaftand
torqueto100ft-lb(135N•m).
7.Rotatethedriveshafttomovethepistonfully
tooneside.Seeinstructionsinstep4of
DisassembletheStandardDiaphragms,page14.
8.Repeattoinstalltheotherdiaphragmassembly.
9.Attachthe󰘱uidcovers.Thearrowoneach󰘱uid
covermustpointtowardtheoutletmanifold.
10.Reassemblethecheckvalvesandmanifolds.
SeeReassembletheBallCheckValve,page11.
11.Restoremotorcoolingfancoverandpin(131)to
theiroriginallocations.
1
Roundedsidefacesdiaphragm.2–Piece 2–Piece
2–Piece( ( (PT PT PTor or orSP SP SP) ) )Models Models Models
2
Applymedium-strength(blue)thread
lockertothethreads.
3
AIRSIDEmarkingsondiaphragmmust
facethecenterhousing.
4
Ifthescrewcomeslooseorisreplaced,
applypermanent(red)threadlocker
todiaphragmsidethreads.Apply
medium-strength(blue)threadlockerto
shaftsidethreads.
5
Torqueto100ft-lb(135N•m)at100
rpmmaximum.
6
Applyprimertothefemalethreads.
Allowtodry.
3A5133J15

Repair
Overmolded Overmolded
OvermoldedDiaphragm Diaphragm DiaphragmRepair Repair Repair
Tools Tools
ToolsRequired Required Required
•28mmopenendwrench
Disassemble Disassemble
Disassemblethe the theOvermolded Overmolded OvermoldedDiaphragms Diaphragms Diaphragms
NOTE: NOTE:
NOTE:Diaphragmkitsareavailableinarangeof
materialsandstyles.SeePartssection.
1.FollowthePressureReliefProcedure,page11.
Removepowerfromthemotor.Disconnectall
hoses.
2.Removethemanifoldsanddisassemble
theballcheckvalvesasexplainedin
CheckValveRepair,page11.
3.Removetheclamps(30)fromthe󰘱uidcovers,
thenpullthe󰘱uidcoversoffofthepump.
4.Toremovethediaphragms,thepistonmust
bemovedfullytooneside.Ifthepumpisnot
attachedtothegearbox,turntheshaftbyhand
tomovethepiston.Ifthepumpisstillattached
tothegearbox,loosenthescrewsandremove
thefancover.Turnthefanbyhandtorotatethe
shafttoshiftthepistontooneside.
TIP: TIP:
TIP:Theaircoverhas2holes(H),oneatthe
9o’clockpositionandanotheratthe3o’clock
position.Usepin(131),placedineitherhole
(H)asabraceforthewrenchwhileremovingor
installingdiaphragmbolts.
a.Holda28mmwrenchonthewrench󰘱atsof
theexposedpistonshaft.Gripthediaphragm
securelyaroundtheouteredgeandrotate
counterclockwise.
b.Rotatethedriveshafttomovethepistonfully
totheotherside.Repeatstep4a.
5.Tocontinuewithdisassembly,see
DisassembletheCenterSection,page18.
Reassemble Reassemble
Reassemblethe the theOvermolded Overmolded OvermoldedDiaphragms Diaphragms Diaphragms
NOTICE NOTICE
NOTICE
Afterreassembly,allowthethreadlockertocure
for12hours,orpermanufacturer’sinstructions,
priortooperatingthepump.Damagetothepump
willoccurifthediaphragmshaftboltloosens.
TIP: TIP:
TIP:Ifyouarealsorepairingorservicingthe
centersection(driveshaft,piston,etc.),see
CenterSectionRepair,page18,beforeyouputthe
diaphragmsbackon.
1.Cleanallpartsandinspectforwearordamage.
Replacepartsasneeded.Besurethecenter
sectioniscleananddry.
2.Thoroughlycleanorreplacethediaphragmbolt
(13).Installtheo-ring(34).
3.Assemblethe󰘱uidsideplate(9),thediaphragm
(11),thebackupdiaphragm(12,ifpresent),and
theairsidediaphragmplate(10)onthebolt
exactlyasshown.
4.Cleanthefemalethreadsofthepistonshaft
withawirebrushdippedinsolventtoremove
anyresidualthreadlocker.Applythread-locking
primerandallowittodry.
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Repair
5.Applymedium-strength(blue)threadlockerto
thethreadsofthebolt.
6.Holda28mmwrenchonthewrench󰘱atsofthe
pistonshaft.Screwtheboltontotheshaftand
torqueto100ft-lb(135N•m).
7.Rotatethedriveshafttomovethepistonfully
tooneside.Seeinstructionsinstep4of
DisassembletheOvermoldedDiaphragms,page
16.
8.Repeattoinstalltheotherdiaphragmassembly.
9.Attachthe󰘱uidcovers.
10.Reassemblethecheckvalvesandmanifolds.
SeeReassembletheBallCheckValve,page11.
11.Restoremotorcoolingfancoverandpin(131)to
theiroriginallocations.
1
Roundedsidefacesdiaphragm.1–Piece 1–Piece
1–Piece( ( (EO EO EO) ) )Model Model Model
2
Applymedium-strength(blue)thread
lockertothethreads.
3
Applyprimertothefemalethreads.
Allowtodry.
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Repair
Center Center
CenterSection Section SectionRepair Repair Repair
Disassemble Disassemble
Disassemblethe the theCenter Center CenterSection Section Section
Seetheillustrationsonpage18.
1.FollowthePressureReliefProcedure,page11.
Removepowerfromthemotor.Disconnectall
hoses.
2.Removethemanifoldsand
checkvalvepartsasdirectedin
DisassembletheBallCheckValve,page11.
3.Removethe󰘱uidcoversand
diaphragmsasdirectedin
DisassembletheStandardDiaphragms,page14.
TIP: TIP:
TIP:Clampthegearboxbracket(15)tothe
bench.Leavethepumpconnectedtothemotor.
4.Usea10mmhexwrenchtoremove4bolts(117).
Pullthepumpoffthealignmenthousing(116).
TIP: TIP:
TIP:Itmaybenecessarytotapthepumpwitha
rubbermallettodisengagethecoupler.
5.Usea5/16hexwrenchtoremovetheplug(124).
Usea30mmsocketwrenchtoremovethe
bearingbolt(106)andtheo-ring(108)fromthe
top.
6.Turnthedriveshaftassembly(112)sothe
grooveontheshaftisatthetop,inlinewiththe
alignmentmarkings.
7.Usea3/4–16bolttopushoutthedriveshaft
assembly(112).Youcanalsousethebearing
bolt(106),butremovethebearing(107)󰘰rst.Be
surethatthegrooveonthedriveshaftremains
alignedwiththemarkingsinthecentersection.
NOTE: NOTE:
NOTE:Removetheboltafterthedriveshaftis
freed
NOTICE NOTICE
NOTICE
Properalignmentisessential.Donotapply
morethanabout10in-lb(1.1N•m)oftorque.
Excessivetorquecouldstripthehousing
thread.Ifyouencounterresistance,check
alignmentorcontactyourdistributor.
8.Theshaftcoupler(113)mightcomeoutwith
thedriveshaftassembly.Ifnot,removefrom
gearbox(118).
9.Removethesealcartridge(110),theo-ring(109)
andtheradialseal(111)fromthedriveshaft
assembly.
10.Slidethepistonassembly(102)outofthecenter.
11.Onlyremovethealignmenthousing(116)if
needed.Usea10mmhexwrenchtoremove4
bolts(120).Pullthealignmenthousingoffthe
gearbox(118).
12.Leavethegearboxcoupler(114)attachedtothe
gearboxshaft(118)unlessitisdamaged.Ifyou
needtoremoveit,abearingpullermustbeused.
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Repair
Reassemble Reassemble
Reassemblethe the theCenter Center CenterSection Section Section
1.Cleananddrythecenterhousing(101),the
centerofthepiston(102)andthedriveshaft
(112).
2.Inspectthepistonandcentersectionbearingsfor
excessivewearandreplaceifneeded.Grease
thepistonasshownandinstallitinthecenter
sectionwiththeslotonthetop,inlinewiththe
alignmentmarkingsinthecentersection.
3.Installtheo-ring(108)andapplymedium-strength
(blue)threadlockertothebearingbolt(106)
andscrewintothecentersection.Besurethat
thebearing(107)isintheslotonthepiston,as
shown.Besurethatthepistonmovesfreely.
Torquetheboltto15–25ft-lb(20–34N•m).
4.Besurethesealingsurfaceofthedriveshaft
(112)isclean.Installthesealcartridge(110)and
theradialseal(111)onthedriveshaft.Thelips
ontheradialseal(111)mustfaceIN IN
INtowardthe
center.Inspectseallipfordamage.Replace
ifnecessary.
5.Installo-ring(109)tothecenterhousing(101).
6.Applyanti-seizelubricantonthematingedgesof
thedriveshaft,asshownintheillustration,page
18.
7.Centerthepistoninthehousingandinstall
thedriveshaftassembly(112)intothecenter
housing(101)withthegroovefacingup.
8.Inspecttheshaftcoupler(113)forwearand
replaceifneeded.Installonthedriveshaft.
9.Ifremoved,installthealignmenthousingtothe
centersection.Applymedium-strength(blue)
threadlockerandinstallthehousingscrews
(117).Torqueto130–160in-lb(15–18N•m).
10.Ifremoved,installthegearboxcoupler(114)
onthegearbox(118)shaft.UseanM12x30
boltandalargewasherinsertedintotheholein
theshafttopressthecouplerintoposition.The
couplerisinproperpositionwhenitis󰘱ushwith
theendoftheshaft.
11.Besurethegearboxcoupler(114)isaligned
properly.Turnbyhandifneeded.Connectthe
pumptothegearboxassembly,engagingthe
couplers.
12.Applymedium-strength(blue)threadlockerand
installthegearboxscrews(120).Torqueto
130–160in-lb(15–18N•m).
13.Besureo-ring(127)isontheplug(124).Install
theplugandtorqueto15–25ft-lb(20–34N•m).
14.SeeReassembletheStandardDiaphragms,
page15,andReassembletheBallCheckValve,
page11.
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Repair
1
Applymedium-strength(blue)thread
lockertothreads.
2
Torqueto15–25ft-lb(20–34N•m).
3
LipsmustfaceIN IN
INtowardthecenter.
4
Applyanti-seizelubricantliberallyon
theradialsurfacesofthedriveshaft
assembly.
5
Installthedriveshaftassemblywith
thegroovefacingup.
6
Tightenscrewsinacrisscross
pattern,5turnsatatime,toengage
thecouplerevenly.Torqueto
130–160in-lb(15–18N•m).
7
Applylubricanttoinnermating
surface.
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